advanced technologies for marabu glass decoration · 2007. 3. 27. · marabu marabuwerke gmbh &...
TRANSCRIPT
Marabu
Marabuwerke GmbH & Co. KG
Advanced
Technologies For
Glass Decoration
Author: Martin Hehl-HeinzProduct Manager GlassMarabu GmbH & Co. KG
Marabu
Marabuwerke GmbH & Co. KGMarabu Today… and
…History
found 1859 in Stuttgart / Germany Headquarter in Tamm near StuttgartFamily business with 450 employees worldwideRepresentations and Subsidiaries in more than 70 countriesScope of business in creative inks as industrial inks forscreen, pad, and digital printing.
In represented since 1990 by Servis Centrum
Marabu
Marabuwerke GmbH & Co. KGMarabu
Overview
• Surface characteristics of glass
• Decoration of Glass
• Pre-treatment
• UV Technology
• Cost comparison screen printing
Ceramic vs. UV
Marabu
Marabuwerke GmbH & Co. KGMarabu
Surface CharacteristicsContainer Glass
Hot-End-Coating
• Is standard practice with beverage bottles
• At approx. 550° - 600°C where a tin (IV)-chloride-film is
applied with a minimum of no less than 30 ctu
• Coating fuses with the glass surface.
Removal is not possible
micro cleft HE Layer
Glass Surface
without with
HE Coating
micro cleftmicro cleftmicro cleft HE LayerHE LayerHE LayerHE Layer
Glass Surface
without with
HE Coating
micro cleft HE LayerHE LayerHE LayerHE Layer
Glass Surface
without with
HE Coating
Marabu
Marabuwerke GmbH & Co. KGMarabu
Surface CharacteristicsContainer Glass
Cold-End-Coating• During labelling, varnishing, and printing, this coating acts like
a separating layer and often causes problems
• Type, thickness, and consistency vary
• The CE-coating provides a better slip for filling lines, protecting
against scratching
The film thickness
nearest the spray
nozzle is
extremely high.
The thickness and
density reduces
significantly the
further from the
nozzle.
Problem Zone for
Labelling
Conveyor Direction
Marabu
Marabuwerke GmbH & Co. KGMarabu
° There is a “fire side“,
° And a “bath“ or “tin side“
° Print onto the fire side! On the tin side flow problems
and bad adhesion are likely
Surface Characteristics Flat Glass
Marabu
Marabuwerke GmbH & Co. KGMarabu
Printing on Glass
Packaging glass� Beverage bottles
� Cosmetic flacons
� Conserve glass
Restaurant glass� Drinking glasses
� Ashtrays
� Cups
Marabu
Marabuwerke GmbH & Co. KGMarabu
Printing on Glass
Packaging glass requirements
• High scratch resistance (transport, filling line)
• Leach (base) resistance (NaOH)
• Humidity resistance (pasteurisation)
• Fill-product resistance (Alcohol, Perfume)
Restaurant glass requirements
• Dishwasher resistance
° Domestic dishwasher, 200 cycles
° Industrial dishwasher, 1200 cycles
• Scratch resistance , fingernail test
Marabu
Marabuwerke GmbH & Co. KGMarabu
Printing on Glass
Flat glass (indoor usage only)
� gambling machines
� furniture (tables, cupboards, showcases)
� mirrors
� tiles
� room and office dividers
� panels for light switches, communicators
Marabu
Marabuwerke GmbH & Co. KGMarabu
Printing on Glass
Flat glass requirements
• Exposed surface
° scratch / rub resistance
° resistance to glass cleaning agents
° short-term resistance to humidity
• Protected surface
° no mechanical requirements
° resistance to chrome-coating (mirrors)
° compatible with laminating agents (tiles, MLG)
° resistance to humidity (bathroom)
Marabu
Marabuwerke GmbH & Co. KGMarabu
Pre-treatment Flaming
The measure of surface wet-ability is the
surface tension (in mN/m). The higher the
surface tension, the better the wet-ability
Marabu
Marabuwerke GmbH & Co. KGMarabu
Pre-treatment Flaming
The exposure to heat with gas flame pre-
treatment breaks the molecule chain on the
substrate surface
Oxygen atoms from the flame bond to these
fissures
Inks adhere to the oxygen bridges
Marabu
Marabuwerke GmbH & Co. KGMarabu
The Pyrosil® or Silan method
° (pyro = flame; sil = Silan -> Silicate coating)
° Through dosage of the silicon based substance into the flame, a highly cross-linked silicone coating is created on the substrate surface
° This silicone coating is extremely beneficial for ink adhesion to glass
Pre-treatmentSilan
Marabu
Marabuwerke GmbH & Co. KGMarabu
The thickness of the densely cross-linked
silicone surface is very thin at between
20 and 40 nm
Figuratively spoken there is an invisibly
thin but enormous rough layer of glass
on the surface
Pre-treatmentSilan
Marabu
Marabuwerke GmbH & Co. KGMarabu
ISIMAT progressed the development of the Pyrosil
method for the decoration of glass with UV-inks
UVitro® -Technology (Patent is announced)
This procedure guarantees excellent long-term
adhesion of UV inks on glass
UVitro® -Technology is possible for all decorations
onto glass
Pre-treatmentUVitro®
Marabu
Marabuwerke GmbH & Co. KGMarabu
Pre-teatmentSilan / UVitro®
Positive Effects
• Increases surface area
• Better surface
wettability
• Increases surface tension
• Treatment in-line, no
additional time required
Influence
• Better mechanical
adhesion
• Better chemical
adhesion
• Better chemical
adhesion
• No additional time
wasting
Marabu
Marabuwerke GmbH & Co. KGMarabu
0
50
100
no pre-treatment flaming Pyrosil UVitro
no pre-treatment flaming Pyrosil UVitro
Comparison of pre-treatment processes regarding adhesion
Pre-treatment Comparison
Marabu
Marabuwerke GmbH & Co. KGMarabu
Silan pre-treatment is a must and the preferred way of pre-treating of beverage bottles and drinking tumblers before printing with UV inks.This way of pre-treatment offers the largest window in production safety.
For pre-treatment of cosmetic bottles and flat glass flame treatment increase adhesion but is not required. However we would always recommend it.
Pre-treatment Summary
Marabu
Marabuwerke GmbH & Co. KGMarabu
UV-technology
Advantages by UV-inks
•unlimited mesh opening
•absence of solvents
• fast drying (curing)
•high production speed
•chemical resistance
and high gloss
•heavy metal free
Marabu
Marabuwerke GmbH & Co. KGMarabu
UV-technology
Advantages by UV-inks
•easy handling of the inks
• increased printing quality
• intermixable basic shades – variety of colour
shades
•no shade deviation with long print runs
• less space for dryer needed
• time savings
Marabu
Marabuwerke GmbH & Co. KGMarabu
UV-technology
Requirements for UV-printing
•UV-dryer unit
•suitable UV-inks
•100 % curing
•adapted mesh and stencil practise
•Tight control of ink deposit
•constant control of sufficient adhesion
•exhaustion of ozone
•careful use of UV-inks
Marabu
Marabuwerke GmbH & Co. KGMarabu
Printing principle on multi-colourmachine
pretreatment 1. print station 2. print station posttreatmentUV-curing UV-curing
Marabu
Marabuwerke GmbH & Co. KGMarabu
Characteristics
° No oven baking is necessary
° Wide colour range. Nearly all Pantone and
HKS colours are possible
° Very fine pigments admit the use of fine
mesh. In due of this printing of very fine
details is possible.
° Very good adhesion and scratch resistance
without baking
° Excellent printability
Printing onto GlassUV Inks
Marabu
Marabuwerke GmbH & Co. KGMarabu
Applications
° Pre-treated, cold-end-coated container glass
such as beverage bottles (only disposable)
° pre- and un-treated cosmetic bottles
° pre- treated restaurant glass such as drinking
glasses, ashtrays, bowls
° pre- and un-treated flat glass for indoor use,
such as mirrors, gambling machines, furniture
Printing onto GlassUV Inks
Marabu
Marabuwerke GmbH & Co. KGMarabu
Resistances° Only disposable bottles with the print in the
labelling field
° Alkali resistance: 2.3 % of NaOH/80°C/40 Minutes
° Pasteurisation: 90°C � 60°C/40 minutes
° Dishwasher resistance domestic dishwasher: min. 500 cycles (65°C/130 minutes)Winterhalter dishwasher: min. 3500 cycles (80°C/3 minutes)
Printing onto GlassUV Inks
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UVMesh Cost/ m²
17
,00
€
28
,60
€
25
,50
€
32
,00
€
18
,60
€
21
,80
€
37
,40
€
78
,25
€
24
,80
€3
1,5
0 €
0,00 €
15,00 €
30,00 €
45,00 €
60,00 €
75,00 €
120 -
34
140 -
31
150 -
31
165 -
27
165 m
esh
200 m
esh
325 m
esh
400 m
esh
on
avera
ge
PolyesterPolyesterPolyesterPolyester MetalMetalMetalMetal
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UVMesh Cost/ m² + Durability
MetalMetalMetalMetal PolyesterPolyesterPolyesterPolyester
costs in %0000
20202020
40404040
60606060
80808080
100100100100
Approximately 40% Cost SavingsEnergy costs to heat screens not taken into account
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UV Ink Consumption /kg
Ink mileage in m²
15,515,515,515,5
25252525
70707070
0 20 40 60 80
Pb/Cd
Pb/Cd Free
UV
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UV Ink Consumption
100%100%100%100%
53%53%53%53%
0%
20%
40%
60%
80%
100%
ceramic UV
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UV Curing/Drying
48 m³/h, Gemco lehr gas
consumption
Running 24 hours
61.44 €/h
9.00 €/h
70.44 €/h
Gas cost lehr
Electricity
TOTAL CERAMIC
360 €/lamp
1500 h operating life
Running only when printing
1.45 €/h
10.50 €/h
11.95 €/h
UV lamps/6 colours
UV Electricity
TOTAL UV
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UV Curing/Drying in %
100%100%100%100%
35%35%35%35%
0%
20%
40%
60%
80%
100%
ceramic UV
Not taking real running time into consideration– lehr runs 24 hours
Marabu
Marabuwerke GmbH & Co. KGMarabu
Cost Comparison Ceramic - UV Printing Cost Analysis in %
6055
35
0
20
40
60
80
100
mes
hin
k
ener
gie
ceramic
UV ink
Marabu
Marabuwerke GmbH & Co. KGMarabu
• EU Guide line 94/62
° limits heavy metal concentration for packaging (100
ppm)
° Up to now no penalties known.
• US - Proposition 65
° Californian law with extensive regulations in connection
to glass and ceramics concerning contact with food.
There are first penalties against PEPSI and COCA COLA
in double digit millions. Dr. Pepper also.
Through this we realised a noticeable increase in
requests for UV-inks and this will become stronger in the
future
° Already having influence to European decorators, too
Printing onto Glass Guidelines
Marabu
Marabuwerke GmbH & Co. KGMarabu
Summary
• Enormous potential
• Cost savings and environment friendly
• Tendency more & more to UV
• UV colours are in a strong position
• This is the time changing over to
decoration with UV inks
Marabu
Marabuwerke GmbH & Co. KG
Thank You For Your Attention!